Systems and methods for producing a ball

ABSTRACT

A sports ball having a high-performance cover formed from a plurality of panels with attached foam backing. The panels may be stitched together at stitch lines which are 2-4 mm from the edges of each of the panels. During manufacturing, before compression is applied, foam attached to outer layers for each of the panels may be a distance 2-6 mm away from the stitch lines. Foam attached on the inside of the sports ball may provide support and a robust round shape for manufacturing of a high performance sports ball.

PRIORITY

This application claims the benefit of priority from Pakistan PatentApplication No. 759/2013, filed Nov. 4, 2013, which is herebyincorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to a ball and a method formanufacturing a ball. More particularly, and without limitation, thepresent disclosure relates to structures and methods for manufacturing asports ball.

BACKGROUND

Conventional hand stitched and thermo bonded soccer balls have numerousdrawbacks related to costs and performance. For example, the labor forhand-stitching balls is expensive since manufacturing a hand-stitchedsoccer ball may take four to six weeks. These balls also use a largeamount of materials including three or more layers of cloth and a largeamount of latex adhesive. Additionally, in hand stitched balls, thestitches are exposed on the surface of the ball. The exposure of thestitches on the surface leads to quicker abrasion of a manufacturedball.

On the other hand, thermo bonded soccer balls do not contain stitchesthat may be exposed on the outer surface, thermo bonded soccer ballshave high transportation costs associated with them since they may notbe deflated. For example, 7500 deflated soccer balls may be packed in atwenty foot container, while only 2,500-3000 thermo bonded soccer ballsmay be transported in the same container-leading to significantly highertransportation costs. Exemplary embodiments, consistent with the presentdisclosure, therefore aim to resolve the aforementioned problems, amongothers.

SUMMARY

An object of the invention is to provide a new and improved soccer ballhaving a high performance, synthetic leather stitched cover thatexhibits softness while maintaining durability.

In an exemplary embodiment, a soccer ball includes a bladder and aplurality of panels stitched together, all but one of the plurality ofpanels consisting of outer layer cutouts that are attached to innerlayer cutouts using adhesive. The outer layer cutouts consist of atleast a fabric, adhesives, and an EPDM foam. The inner layer cutoutsconsist of ethylene propylene diene monomer (EPDM) foam that is the sameshape as corresponding outer sheet cutouts but of a smaller size, andthe inner layer cutouts extend to stitch lines on the outer layercutouts, a distance between edges of the other layer cutouts and thestitch lines is 2-3 mm. Furthermore, a bladder valve panel of theplurality of panels consists of an outer layer cutout attached to abladder valve panel inside layer consisting of multiple layers of fabricand multiple layers of adhesives, and including a valve that is attachedto the bladder.

In an exemplary embodiment, a manufacturing method of a soccer ball isprovided. Exemplary methods include cutting outer layer cutouts from anouter layer for two or more panels, the outer layer consisting at leastof a fabric, ethylene propylene diene monomer (EPDM) foam, cutting innerlayer cutouts for the two or more panels from an inner layer consistingof EPDM foam, adhesive, and a plastic sheet, the inner layer cutoutsbeing the same shape as corresponding outer sheet cutouts but of asmaller size, and cutting a bladder valve panel inside layer from asheet consisting of multiple layers of fabric, multiple layers ofadhesives, and a plastic sheet, the bladder valve panel inside layer ofthe same size and shape as the inner layer cutouts. The method furtherincludes forming a bladder valve panel by applying an adhesive to anexposed surface of one of the outer layer cutouts and removing theplastic sheet to expose an adhesive layer from the bladder valve panelinside layer and attaching the remaining multiple layers of fabrics andmultiple layers of adhesive to the exposed surface of the one of theouter layer cutouts. The method further includes attaching a bladder tothe bladder valve panel and inserting a valve attached to the bladder inthe middle of the bladder valve panel, determining stitch lines on eachof the outer layer cutouts, the stitch lines closer to edges of each ofthe outer layer cutouts than edges of a corresponding inner layercutout, stitching a plurality of the outer layer cutouts together usingmachine stitching at the stitch lines, applying adhesive to exposedsurfaces of all remaining outer sheet cutouts other than the cutout usedin the bladder valve panel, removing the plastic sheets of the innersheet cutouts to expose respective adhesive layers of each of the innersheet cutouts and attaching the respective EPDM foams to the exposedsurfaces of all remaining outer sheet cutouts, and inverting the soccerball inside out so that the bladder is contained within the soccer ball.The method further includes hand stitching any remaining unstitchedstitch lines and inserting air in the bladder and applying heat to thesoccer ball in a ball molding device to compress the EPDM foams toextend to the stitch lines.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate exemplary embodiments of thepresent disclosure and, together with the description, serve to explainthe principles of the disclosure.

FIG. 1 shows a cross-section of materials comprising an outer layer ofpadding of a soccer ball, consistent with exemplary embodiments of thepresent disclosure;

FIG. 2 shows a cross-section of materials comprising an inner layer ofpadding of a soccer ball, consistent with exemplary embodiments of thepresent disclosure;

FIGS. 3A and 3B are illustrations of an exemplary scenario for cuttingout panel shapes, consistent with exemplary embodiments of the presentdisclosure;

FIGS. 4A-D illustrate an exemplary scenario for stitching two panelstogether, consistent with exemplary embodiments of the presentdisclosure;

FIGS. 5A-C are different views of a panel with outer layer and innerlayer attached to each other, consistent with exemplary embodiments ofthe present disclosure;

FIGS. 6A-6J illustrate various shapes of panels, consistent withexemplary embodiments of the present disclosure;

FIGS. 7A and 7B illustrate exemplary steps for creating a bladder valvepanel, consistent with exemplary embodiments of the present disclosure;

FIGS. 8A and 8B illustrate exemplary bladders, consistent with exemplaryembodiments of the present disclosure;

FIGS. 9A and 9B illustrate exemplary bladders attached to respectivebladder valve panels, consistent with exemplary embodiments of thepresent disclosure; and

FIGS. 10A-C illustrate some exemplary steps for stitching panels of asoccer ball, consistent with exemplary embodiments of the presentdisclosure.

DETAILED DESCRIPTION

A soccer ball is made up of two major components, a bladder and a coverof panels. Embodiments consistent with the present disclosure enhancethe performance of a soccer ball by providing a method and structure forefficient stitching of panels and providing these panels with areinforced support using foam. Specifically, exemplary embodimentsprovide for stitching together cutouts of an outer layer of a padding,and then attaching foam of a similar shape but a smaller size to each ofthe cutouts. When an air bladder included within a soccer ball is filledand molding is applied to the soccer ball, the attached foams arecompressed and expand to stitch lines of the cutouts of the outer layer,creating a reinforced panel support system. The reinforced panel andmolding of a soccer ball allows for uniformity and consistency in theshape of a soccer ball. Accordingly, soccer balls that are manufacturedby using exemplary methods may have better performance and outerappearance than hand-stitched and thermo bonded balls. By creating areinforcing padding system using exemplary methods, a mostly machinedstitched soccer ball may have the appearance and performancecharacteristics of a thermo bonded ball while at the same time theability to be deflated similar to a hand-stitched ball.

FIG. 1 shows a cross-section of materials comprising an outer layer 100for panels of a soccer ball, consistent with exemplary embodiments ofthe present disclosure. Outer layer 100 may include an outer materialsheet 102 which may be a layer of Polyvinyl Chloride (PVC), Polyurethane(PU), or a similar synthetic material. Outer material sheet 102 may belaminated to a first layer of ethylene propylene diene monomer (EPDM)compound foam 106. In embodiments, outer material sheet 102 may have athickness of 0.3-2.0 mm and foam 106 may have a thickness of 2-3 mm Thelamination may be completed using an adhesive 104, such as a latexadhesive. A thin layer of cloth or fabric 110 may then be attached onback of foam 106, using another layer of adhesive 108, such as a latexadhesive. In embodiments, fabric 110 may have a thickness of 0.3-1.0 mm.In embodiments, outer layer 100 may be heated and dried for apre-determined period. For example, outer layer 100 may be dried at 55degrees Celsius for up to one hour. In embodiments, total thickness ofouter layer 100 may be 4.6-6 mm.

FIG. 2 shows a cross-section of materials comprising an inner layer 200for panels of a soccer ball, according to an embodiment of the presentdisclosure. Inner layer 200 may include EPDM compound foam 206. Inembodiments, EPDM foam 206 may have a thickness of 2-3 mm. In additionalembodiments, a thickness of EPDM foam 206 may be dependent on thetexture of the material and its ability to expand under compression. Forexample, as will be apparent later, foam 206 may need to expand acertain distance when compression is applied, therefore a particularthickness will be needed for foam 246 to expand a certain distance whena particular amount of pressure and/or heat is applied. Foam 206 may belaminated to plastic sheet 202 using adhesive layer 204, such as a latexadhesive. In embodiments, as explained below in further detail, removingthe plastic sheet will allow the EPDM foam 206 to be attached to outerlayer 100. In embodiments, plastic sheet 202 may be polyethylene orpolypropylene. In embodiments, total thickness of inner layer 200 may be0.45-0.55 mm.

FIGS. 3A and 3B are illustrations of an exemplary scenario for cuttingout panel shapes, according to an embodiment of the present disclosure.Layer 300 may represent either inner layer 100 or outer layer 200. In anexemplary embodiment, corresponding cutouts of outer layer 100 and innerlayer 200 for soccer ball panels may have the same shape but differentsizes. Specifically, a cutout of inner layer 200 may be smaller is sizethan a cutout of outer layer 100. That is, for a hexagonal panel, ahexagonal cut out from outer layer 100 may be cut and a correspondingsmaller hexagonal cut out from inner layer 200 may be cut. As shown inFIG. 3A, required panel shapes (304, 306, and 308) may be cut from layer300 using conventional ball cutting knives. FIG. 3B illustrates anexemplary cutout 310 that may be cut from layer 300. In this exemplaryscenario, cutout 310 may represent a cutout of outer layer 100. Cutout310 is hexagon shaped to form a hexagon shaped panel.

FIG. 4A-4D are cross-sections of exemplary steps in the forming ofpanels of a soccer ball, consistent with embodiments of the presentdisclosure. One of ordinary skill in the art will comprehend, that theelements illustrated within FIGS. 4A-4D are not drawn to scale. Instead,they have been illustrated in sizes that allow for easier comprehension.

FIG. 4A illustrates two cutouts 402 and 404 side-by-side. In anexemplary embodiment, cutouts 402 and 404 may be cutouts from outerlayer 100. Accordingly, cutouts 402 and 404 may be respective cutouts ofrespective layers of fabric 110, adhesive 108, foam 106, adhesive 104,and outer material 102. Stitch lines 410, 412, 414, and 416 mayrepresent locations on cutouts 402 and 404 where stitching may beapplied. Each cutout of outer layer 100 may contain stitch lines similarto stitch lines 410, 412, 414, 416 illustrated on cutouts 402 and 404.In an exemplary embodiment, the stitch lines may be a pre-determineddistance from the edges of cut outs of outer layer 100. Further detailsregarding stitch lines is provided along with description accompanyingFIGS. 5A-C.

FIG. 4B illustrates stitch regions 430 and 432 of the two cutouts 402and 404 turned up. Stitch regions may refer to regions from respectivestitch lines to respective edges of cutouts of the outer layer 100. Forexample, from stitch lines 410, 412, 414, and 416 to edges of cutouts402 and 404. In embodiments, an aspect of the step illustrated in FIG.4B is that the stitch regions of two cutouts are placed next to eachother for stitching so that they may be stitched together at stitchlines 412 and 414. In embodiments, two respective cut outs necessarilydo not need to be flat side-by-side, rather, in a position where twocutouts may be stitched together at stitch lines. In embodiments, anaspect of the step illustrated in FIG. 4B-4D is that the stitching isapplied at respective stitch lines 412 and 414 with surfaces of therespective outer material 102 being in contact with each other.Accordingly, after all panels are stitched together, any machinestitching may be contained within a soccer ball. Additionally, fabriclayers (fabric 110) may also be contained within the ball, as isapparent by the additional description provided in the disclosure.

FIG. 4C illustrates stitching 420 at stitch lines 412 and 414 thatstitches together cutouts 402 and 404. Stitching 420 may be applied toall stitch lines of a cutout for a first panel with cutouts for variousother panels. For example, a hexagonal shaped cutout may be stitchedtogether with six other cutouts, each of the six cutouts forming partsof six respective panels of a soccer ball. In embodiments, stitchingmaterial may be high strength polyester, or polyester cotton mix highstrength applied by a stitching machine, such as a high tensionstitching machine. A high tension stitching machine may apply very hightension on a thread enabling the stitches to be invisible on the outershell of a manufactured soccer ball.

FIG. 4D illustrates application of cutouts of inner layer 200 tostitched together cutouts 402 and 404, according to exemplaryembodiments consistent with the present disclosure. In this exemplaryscenario, foam 206 and adhesive 204 may be respective layer cutouts ofinner layer 200. First, adhesive 422, such as a latex adhesive, may beapplied on the exposed surface of fabric 110 that is not part of thestitch region. Adhesive 422 may be hand-applied or applied automaticallyby machines. Then, a cutout of plastic sheet 202 may be peeled off fromadhesive 204, exposing adhesive 204, which may be a latex adhesive.Therefore, adhesives 422 and 204 may be used for attaching foam 204 tofabric 110. In embodiments, there may be a gap between stitching 420(that is, stitching lines 410 and 412) and foam 206. As described later,application of compression and/or heat to foam 206 may lead the foam 206to extend to stitching 420, at respective stitch lines of variouspanels.

In embodiments, only one of adhesives 204 and 422 may be used forattaching foam 206 to fabric 110. For example, a cutout of foam 206 maybe attached directly to fabric 206 using only adhesive 422. However, anaspect of exemplary embodiments is that the width of foam 426 is lessthan any stitch lines on a cutout of outer layer 100.

FIG. 5A-5C are different views of a panel with cutouts of an outer layerand an inner layer attached to each other, according to an embodiment ofthe present disclosure. Exemplary panel 500 illustrates a singular panelas it may appear after the steps illustrated in FIGS. 4A-D have beenapplied. FIGS. 5A-5C illustrate the difference in size between cutoutsof outer layer 100 and inner layer 200. For example, FIG. 5A illustratesa top view of cutout 310 attached to cutout 502 (which may be a cut outof inner layer 200). Both cutout 310 and cutout 502 are of similarshape, but cutout 502 is smaller in size. As discussed above, aftercutting out cutout 502 from inner layer 200, plastic sheet 202 isremoved. Thereafter, using adhesive layer 204, EPDF foam 206 may beattached to cutout 310. Stitch line 504 may represent where stitchingmay be applied to attach panel 500 to other panels.

As illustrated in a cross-section of panel 500 illustrated in FIG. 5B, adistance 520 between the edge of cutout 502 and cutout 310 may be 4-10mm. Additionally, distance 522 between stitch line 504 and edge ofcutout 310 may be 2-4 mm. As discussed above, and explained in furtherdetail below, the gap/cavity between cutout 502 and stitch line 504 maybe covered due to the application of pressure on cutout 502 which maycomprise of EPDM foam. The gap/cavity between cutout 502 and stitch line504 may be of 2-6 mm. In some embodiments, the gap/cavity between cutout502 and stitch line 504 may a function of the thickness of EPDM foam incutout 502 or the properties of EPDM foam to expand by application ofpressure and/or compression. In embodiments, distance 522 may be equalto or more than two-thirds of a distance than distance 520.

FIG. 5C, illustrates a three-dimensional view of panel 500. Inembodiments, the three-dimensional view of panel 500 provides a furtherperspective indicating the size difference between cutout 310 and cutout502, in addition to the placement of stitch line 504.

FIGS. 6A-6J illustrate various shapes of panels, consistent withexemplary embodiments of the present disclosure. FIG. 6A illustratespentagon-shaped panel 600 comprising outer layer cutout 602 attached toinner layer cutout 604. Similarly, FIGS. 6B-6J, illustrate differentshaped panels 610, 620, 630, 640, 650, 660, 670, 680, and 690, that eachinclude respective outer layer cutouts 612, 622, 632, 642, 652, 662,672, 682, 692, and corresponding respective inner layer cutouts 614,624, 634, 644, 654, 664, 674, 684, and 694.

In embodiments, different shaped panels may be stitched to each other.For example, round-shaped panel 650 may be stitched panel 640. However,for each panel of a soccer ball, a size of a cutout of inner layer 200may be less than a cutout of outer layer 100.

FIGS. 7A and 7B illustrate exemplary steps for creating a bladder valvepanel, consistent with exemplary embodiments of the present disclosure.A bladder valve panel may refer to a panel of a soccer ball that has abladder attached to it and contains a valve for filling air into thebladder or for deflating the bladder. For example, FIG. 7A, illustratesanother a cutout of bladder valve panel inside layer 700, consistentwith exemplary embodiments of the present disclosure. In embodiments, acutout of bladder valve panel inside layer 700 is a cutout of a similarshape as a cutout of inner layer 200 corresponding to a cutout of outerlayer 100. Accordingly, bladder valve panel inside layer 700 may beattached to cutout 310 of outer layer 100 to form a bladder valve panel.In detail, inner layer 700 consists of four layers of fabric 706, 710,714, 718, laminated together with adhesives 708, 712, and 716. Plasticsheet 702, similar to plastic sheet 202, may be attached to fabric 706using adhesive 704. Adhesives 704, 708, 712, and 716, may be a latexadhesive. In exemplary embodiments, additional or lesser layers offabric may be used interspersed with adhesives with a thicknessequivalent to or similar to thickness of EPDM foam 206. Using innerlayer 700 to attach to cutout 310 for forming a valve panel allows forpreventing bumps on a soccer ball that may be caused if EPDM foam 206 isused as part of the bladder valve panel. Therefore, exemplary methodsallowing for using the bladder valve panel along with other panelsallows for overall uniformity, balance, and precision in a soccer ball.

FIG. 7B illustrates application of a cutout of bladder valve panelinside layer 700 to cutout 402, according to exemplary embodimentsconsistent with the present disclosure. In this exemplary scenario,first, adhesive 422, such as a latex adhesive, may be applied on theexposed surface of fabric 410 that is not part of any stitch region,that is, internal to stitch lines 410 and 412. Then, plastic sheet 702may be peeled off from adhesive 704, exposing adhesive 704, which may bea latex adhesive. Therefore, adhesives 704 and 422 may be used forattaching foam 424 to fabric 706. Additionally, a cavity may be createdin the middle of the bladder valve panel where valve 724 may beinserted. Valve 724 may be attached to bladder flap 722. As explained infurther detail along with the explanation of FIGS. 8A and 8B, bladderflap 722 may refer to a portion of an exemplary bladder that may beattached to a bladder valve panel. Adhesive 720 may be applied betweenbladder flap 722 and fabric layer 718 attaching bladder flap 722 to thebladder valve panel.

In embodiments, a bladder valve panel may be created by inserting valve724 attached to bladder 724 in a panel created using the exemplarymethod illustrated in FIGS. 4A-D and FIGS. 5A-C.

FIGS. 8A and 8B illustrate two exemplary bladders 800 and 802,consistent with exemplary embodiments of the present disclosure.Bladders 800 and 802 are both attached to exemplary valve 724. Inembodiments, adhesive may be applied to portions of bladders 800 and 802(bladder flap 722) surrounding valve 724 so that bladders 800 and 802may be permanently attached to a bladder valve panel. Bladder 800 may beany molded rubber or butyl or synthetic rubber that may be wound withpolyester or nylon threads. Bladder 802 may be a molded rubber or butylbladder or synthetic rubber that may be laminated with polyester orpolyester cotton cloth strips. In embodiments, additional bladders, withrestricted circumference properties may be used. In exemplaryembodiments, valve 724 may be used for inflating or deflating bladders800 and 802. Exemplary bladders aid in providing firmness and roundnessto a soccer ball. FIGS. 9A and 9B illustrate the two exemplary bladders800 and 802, attached to respective bladder valve panels (consisting ofcutout 310 of outer layer 100 and a cutout of bladder valve panel insidelayer 700 which has the same dimensions as a cutout of inner layer 200).An exemplary bladder valve panel may be stitched together withadditional panels formed using the method illustrated in FIGS. 4A-D and5A-C to form a soccer ball.

In exemplary embodiments, most of the cutouts of outer layer 100 for thepanels are machine-stitched together, with the fabric layers 110 beingexposed on the outside of the soccer ball when machine stitching isbeing applied. Then, after cutouts of inner layer 100 are attached, theball may be inverted inside out, where the bladder is contained withinthe soccer ball. Hand stitching may then be applied to any remainingun-stitched panel edges. In embodiments, only an amount of panels edgesare left for hand stitching that are needed to invert a soccer ballinside out so that the bladder is contained within the stitched-togetherpanels. In embodiments, a length of panel edges where hand-stitching maybe applied is four to six inches.

FIGS. 10A-C illustrate some exemplary steps for stitching panels of asoccer ball, consistent with exemplary embodiments of the presentdisclosure. FIG. 10A illustrates soccer ball 1000 with various panels.Numerous panels and/or panel edges of soccer ball 1000 are stitchedtogether using machine stitching 1012 as discussed above with respect toFIGS. 4A-4D. A cavity 1002 exposing bladder 802 may be hand-stitchedusing string 1004. FIG. 10B illustrates a second stage of hand stitchingwhere panels are pulled closer together and string 1004 may be beingapplied at exemplary position 1006. FIG. 10C illustrates a completedstitched soccer ball 1000 with majority of the panels and/or panel edgesbeing stitched together by applying machine stitching 1012. Four paneledges are stitched together using hand stitching 1010.

In embodiments, once the machine and hand stitching is complete, abladder contained within a soccer ball may be completely filled withair. Then, the soccer ball may be placed in a heated molding machinewhich is round in the finalized shape of a soccer ball. Heating underpressure of the inner cover of a molding machine may then be applied tothe soccer ball for providing a permanent shape to the soccer ball. Insome embodiments, the soccer ball may be molded at 70 degrees Celsiusfor thirty seconds to sixty seconds. Accordingly, a total of sixtysecond of heat of 70 degrees Celsius may be applied to the soccer ball.In embodiments, EPDM foam contained on the inside of each panel may bemoldable at 60 degrees Celsius to 80 degrees Celsius. Therefore, theball sets uniformly from outside through the pressure generated owing tothe hot mold and inside due to the pressure from the bladder. Inembodiments, any space left between EPDM foam padding and stitch linesare filled because of the pressure applied by the bladder and themolding. Therefore, the moldable property of EPDM foam may allow forcreation of a uniform surface on the inside of the ball as well as themolding providing a uniform surface on the outside of the football. Inembodiments, the exemplary manufacturing methods provide for a robustsoccer ball where the EPDM foam provides a foam support structuresurrounding the bladder and reinforcing the outside cover.

In embodiments, any seams in a ball may be sealed by application ofsealants before or after molding. Exemplary sealants may includepolyurethane liquids among others.

In embodiments, exemplary soccer balls manufactured according toexemplary methods aid in reducing manufacturing costs significantly,while at the same time, the ball rebounds, has waterresistance/absorption, and has abrasion properties that are superior tothe characteristics of current hand stitched and thermo bonded balls.Furthermore, the ability to transport these balls while they aredeflated also leads to numerous commercial advantages such assignificant reduction of cost compared to transportation of thermobonded balls.

In some embodiments, the exemplary methods of stitching together panelswith foam support may be applied in any types of balls that utilizepanels and bladders, such as footballs, rugby balls, volleyballs, waterpolo balls, handballs etc.

What is claimed:
 1. A manufacturing method of a soccer ball, comprisingthe steps of: a. cutting outer layer cutouts from an outer layer for aplurality of panels, the outer layer comprising a fabric and ethylenepropylene diene monomer (EPDM) foam, b. cutting inner layer cutouts forall but one of the plurality of panels from an inner layer comprisingEPDM foam, adhesive, and a plastic sheet, the inner layer cutouts beingthe same shape as corresponding outer layer cutouts but of a smallersize; c. cutting a bladder valve panel inside layer cutout from a sheetcomprising multiple layers of fabric, multiple layers of adhesives, anda plastic sheet, the bladder valve panel inside layer cutout of the samesize and shape as the inner layer cutouts; d. forming a bladder valvepanel by: i. applying an adhesive to an exposed surface of one of theouter layer cutouts; and ii. removing the plastic sheet of the bladdervalve panel inside layer cutout to expose an adhesive layer andattaching the remaining multiple layers of fabrics and multiple layersof adhesives to the exposed surface of the one of the outer layercutouts; e. attaching a bladder to the bladder valve panel and insertinga valve attached to the bladder in the middle of the bladder valvepanel; f. determining stitch lines on each of the outer layer cutouts,the stitch lines at a distance from edges of each of the outer layercutouts that is less than the size difference between correspondinginner layer cutouts and outer layer cutouts; g. stitching a plurality ofthe outer layer cutouts together using machine stitching at the stitchlines; h. applying adhesive to exposed surfaces of all remaining outerlayer cutouts other than the one of the outer layer cutouts used in thebladder valve panel; i. removing respective plastic sheets of the innerlayer cutouts to expose respective adhesive layers of each of the innerlayer cutouts and attaching respective EPDM foams to the exposedsurfaces of all remaining outer layer cutouts; j. inverting the soccerball inside out so that the bladder is contained within the soccer ball;k. hand stitching any remaining unstitched stitch lines; and l.inserting air in the bladder and applying heat to the soccer ball in aball molding device for compressing the respective EPDM foams of theinner layer cutouts to extend to the stitch lines.
 2. The method ofclaim 1, wherein determining stitch lines on each of the outer layercutouts comprises determining that a location of the stitch lines iscloser to the edges of each of the outer layer cutouts than edges ofcorresponding inner layer cutouts once they are attached.
 3. The methodof claim 1, wherein determining stitch lines on each of the outer layercutouts comprises determining that a distance between edges of the otherlayer cutouts and the stitch lines is 2-4 mm and a distance between theedges of the other outer layer cutouts and edges of any attachedrespective EPDM foams before compression is applied is 2-6 mm.
 4. Themethod of claim 1, wherein after step i, the stitch lines are 2-6 mmfrom edges of respective EPDM foams.
 5. The method of claim 1, wherein athickness of the bladder valve panel is equal to a combined thickness ofthe outer layer and the inside layer.
 6. The method of claim 1, whereinthe exposed surfaces of all remaining outer layer cutouts are fabric. 7.The method of claim 1, wherein the hand stitching is applied for four tosix inches.
 8. The method of claim 1, wherein the soccer ball comprisesthirty-two panels.
 9. A manufacturing method of a soccer ball,comprising the steps of: a. cutting outer layer cutouts from an outerlayer for a plurality of panels, b. cutting inner layer cutouts for allbut one of the plurality of panels from an inner layer includingethylene propylene diene monomer (EPDM) foam, the inner layer cutoutsbeing the same shape as corresponding outer layer cutouts but of asmaller size; c. cutting a bladder valve panel inside layer cutout froma sheet comprising multiple layers of fabric and multiple layers ofadhesives, the bladder valve panel inside layer cutout of the same sizeand shape as the inner layer cutouts; d. forming a bladder valve panelby attaching the bladder valve panel inside layer cutout to one of theouter layer cutouts; e. attaching a bladder to the bladder valve paneland inserting a valve attached to the bladder in the middle of thebladder valve panel; f. determining stitch lines on each of the outerlayer cutouts, the stitch lines closer to edges of each of the outerlayer cutouts than edges of a corresponding inner layer cutout that isto be attached; g. stitching a plurality of the outer layer cutoutstogether using machine stitching at the stitch lines; h. attaching innerlayer cutouts to exposed surfaces of all remaining outer layer cutoutsthat are not part of the bladder panel valve; i. inverting the soccerball inside out so that the bladder is contained within the soccer ball;j. hand stitching any remaining unstitched stitch lines; and k.inserting air in the bladder and applying heat to the soccer ball in aball molding device to compress respective EPDM foams of the inner layercutouts to extend to the stitch lines.
 10. The method of claim 9,wherein the exposed surfaces of all remaining outer layer cutouts arefabrics.
 11. The method of claim 9, wherein the hand stitching isapplied for four to six inches.
 12. The method of claim 9, wherein thesoccer ball comprises of thirty-two panels.